Process of filling shoes



May 17, 1932. AJTHOMA PROCESS OF FILLING SHOES Filed Aug. 4, 1927 2 Sheets-Sheet 1 DA Mm 2 .6 0 i 7 J z a j g "n Z w May 17, 1932. A. THOMA 1,859,257

PROCESS OF FILLING SHOES Filed Aug. 4, 1927 2 Sheets-Sheet 2 VII/IA Patented May 17, 1932 ears STAT ANDREW THOMA, OF CAMBRIDGE, MASSACHUSETTS, ASSIGNOR TO NORTH AMERICAN CHEMICAL COMPANY, CHUSETTS 9F BOSTON, lti-ASSACHU'SETTS, A CORPORATION" OF MASSA- PROCESS' OF FILLING SHOES Application filed was, 1927. seriain 210,558.

This invention pertains to the manufacture of shoes and relates more particularly to a process of filling shoe bottoms, the present application being a continuat1on 1n part of my copending application Ser al No. 133,506, filed September 3, 1926. My preferred process or method of filling shoebottoms (particularly McKay shoes) is new 1n providing a filler piece, preferably a spreadable piece, that is capable of holding an external film of water or other liquid capable of keeping the filler piece positioned as placed by the operator until at least the sole fastening operation, immersing or wetting sald piece (preferably throwing a number thereof into a water container), and then placing the wetted piece in filler laying position; it is new in then placing it and securing it on the outer sole, or, if preferred, in the shoe-bottom cavity. The further preferable step of thorough wetting or otherwise condltloning the filler material (in addition to or aside from the step of causing adhesion just mentioned) prior to its application is new, as further elaborated later herein and is broad ly claimed in my application Senal No. 2-=l2,085, filed December 23, 1927,'wh1ch in part is a continuation of the present appllcation. Also, further enumerating the broadly new features claimed and hereinafter set forth in detail, my process or method is new in positioning the spreada-ble filler layer to its linal or ultimate position by means of pressure which is solely vertical, i. e. .perpendicular to the shoe bottom as d1st1nguished from the lateral or back and forth movement heretofore (of the heated laying roll or trowel-like knife in the hand of the operator). It is new in accomplishing the final positioning ofthe entire fillerlayer by asingle pressure. It is new in applying the pressure for molding or spreading the filler into all parts of the cavity through or by the aid of the sole. It is new in using and employing the sole leveling pressure as the filler spreading and expanding pressure. It is new in first applying a filler piece so as to occupy less than the entire area of the shoe-bottom cavity at least a portion of which filler piece is distensible or expansible' and then expanding said fill-er piece to its ultimate cavity filling position by meansof said vertical pressure, preferably through the sole, and preferably by thesoleleveling operation. It is new in doing theforegoing cold, i. e. at normal or working temperatures as distinguished from requiring temperature treatment, either hot or cold. It is new in providing as an article of manufacture a self-sustaining or shape maintaining filler piece which is expansible, placing the same in the shoe-bottom cavity between the inner sole and outer sole and then expanding it within the confines of the cavity.

It is new to interpose between the inner sole and outer sole spreadable filler material in the shoe-bottom cavity and then spreading it to finalposition for holding and in such manner as to support said two soles as a unit; It is new to cause said-two soles and the filler to function together as a unit. These and other features enumerated toward the end of this description are the prominent features of novelty but many subordinate or lesser features will be apparent from the following description and as defined in the appended claims, I

In "a long series of'patents, of which I cite No. 808,224, December 26, 1905, and No. 832,002, September 25, 1906, as specific examples, I have disclosed certain shoe-bottomfiller compounds which are generally similar in respect to the following characteris' tics, to wit: They are permanently sticky, resilient, pliable, and compressible when cold, extremely adherent to leather, waterproof or water-repellent, capable of becoming fluid or semi-fiuid when heated, non-inflammable, heat-insulating, and relatively non-shifting when confined as a filler within the cavity of a shoe bot-tom.

As described in my prior patents, this filler material is disposedin the shoe-bottom cavity while in a plastic semi-fluid state, and is spread while still plastic by means of suitable instrumentalities, for example a broad bladed knife. In order to spread the material in this manner it is necessarythat it be semi-fluid, and in applying filler of this general character heat has always been employed and considered necessary at one or another stage of the filling process in order to reduce the filler to the proper degree of fluidity for spreading and then the spreading is done by a lateral or forward and back trowel-like movement over the shoe-bottom cavity.

In my 'copending application Serial No. 183,302, filed April 13, 1927, I describe a novel form of filler having in general the same characteristics as my prior patented filler "com pounds, notably the permanent stickiness, elasticity, pliability and waterproof qualities of such compounds but embodied in a coherent self-supporting layer or sheet-like piece of a shape approximating that of the cavity in the shoe bottom and applicable to the shoe while cold, that is, at normal room tem-' room, and the facility With which the filler material may be handled, shipped and stored. In my copending applications Serial N0. 211,157 filed August 6, 1927, Serial No. 228,236 filed October 24;, 1927, SerialNo. 228,588 filed October 25, 1927, Serial No. 232,279 filed November 10, 1927 and Serial No. 242,085 filed December 23, 1927 other advantages are set forth.

' Not only does'the novelfiller leaf or artiole, as disclosed inmy aforesaid copending' applications, facilitate the manufacture of a shoe in the above particulars, but it .has additional advantages, among which I note its applicability to shoes of the McKay type, wherein the cavity in the shoe bottom is shallow so that proper spreading and evening of the semi-fiuid-filler by my old process is difiicult'or impracticable and where, owing to the relative cheapness of such shoes, the cost of the spreading operation is practically prohibitive. On the other hand,the McKay type of shoe presents-certain structural characteristics making it difficult properly to fill it with other types of filler. Thus, in the McKay shoe the marginal portion ofthe upper is disposed in folds 0r pleats upon the innerv sole and the cavity definedby the edge of the upper varies in size and is of irregular and non-uniform outline so that'solid filler pieces of felt, leather-board, or the like, rarely fit the cavity and almost never provide a smooth and uniform surface extending over the entire bottom of the shoe for.

contact with the inner surface of the outer sole, and hence the outer sole is improperly supported, Wears unevenly, and the resulting shoe is uncomfortable to the wearer. Furthermore, the McKay type of shoe is prone to squeak due to the frictional contact of the inner sole and outer sole against each other or against the intervening dry and solid filler elements.

I have succeeded by my present invention in making it practicable to employ my old type of filler. in the McKay typeof shoe, but in such novel method and structure as to eliminate the diflic-ulties and objections above explained and also'the undesirable features that they function as a unit. Thus, it is possible, if desired, to use a cheaper or thinner inner sole than usual without substantial sacrifice of strength or wearing qualities. I will hereinafter more fully describe the process by which I obtain these desirable results, having reference to the accompanying drawings for illustration of a certain desirable sequence of steps comprised in my preferred process, togetl1er with apparatus and appliances useful in performing somev of said steps,

it being understood that these illustrations aremerely by way of example of a desirable sequence of steps and are not restrictive of the invention or. conclusive of the number or order of the steps employed or of the appara tus used in performing the individual steps or the process as a whole. Moreover, while as illustrated the process is shown as applied to the filling of a McKay shoe, it is not intended, except in its more limited aspects, to restrict it to thisuse or environment.

In the drawings: 1 Fig. 1 isa fragmentary vertical section, to large scale, showing a preferred form of filler employed in my present process; Figs. 2 and 3 are views similar to Fig. '1, but showing modified forms of filler; Fig. 4 is a perspective view illustrating a step in the process of preparing filler pieces or leaves of the type which I employ;

Fig. 5 is a perspective view illustrating a later step in said process;

Fig. 6 is a fragmentary. diagrammatic plan view illustrating a mode of procedure alternative to that illustrated in Figs. 4 and 5;

Fig. 7 is a plan view of a string-like series of united filler pieces;

Fig. 8 is a perspective view illustrating a single filler piece or leaf. resulting from the process steps illustrated in Figs. 4: and 5; V 1 Fig.19'is a perspective view illustrating one mode of separating connected filler pieces in accordance with my present invention;

Fig. 10 is a plan View of a filler piece or leaf of a difierent shape, prepared for attaching it to a shoe bottom;

. Fig. 11 is a diagrammatic plan View illustrating filler pieces of various shapes;

Fig. 12 is a diagrammatic plan view of tne bottom of McKay shoe prior to application the outer sole and illustrating one step of my present process;

Fig. 13 is a transverse section, to larger scale, substantially on the line 18-13 of Flg.

Fig. 14 a section showing the outer sole in position and indicating the appearance of the filler piece after the, leveling operation; and

Fig. 15 is'a diagrammatic plan view showing the appearance of the bottom of a Mo- Kay shoe after leveling and with the outer sole removed. I

In the practice of my present process 1 prefer to employ for the best and most complete results a filler leaf or piece 'of coherent selfsupporting character comprising a plastic, sticky and waterproof layer of shoe of the general character disclosed. in any of my patents cop-ending applications above referred to, although in its broader aspects my present process is not necessarily confined to the employment of such a filler leaf. Preferably also the filler material is of the modified kind of my cepending application Serial No. 211,157, filed August 6, 1927, comprising or least containing in part an ingredient or a compound such as water alone or one of colloidal nature such as gluey or gelatinous material or materials which are changeable by pressure; for instance, an emulsion of vegstable or mineral compounds, gelatin, glue, or anything of a colloidal nature that can be made to have proper fluidity to break down under pressure. In the case of a pressure release thus of water from the compound the water simply evaporates so that it results that the filler layer has been made by the pressure step stiffer or inherently more stable in position as a part of the shoe bottom. An example of this is milk of magnesia which when pressed between absorbent surfaces quickly dries or, in other words, to the eX- tent ,of its entering into the filler, it acts, under the leveling pressure, to stiffen the general filler body and render its less shifting in tendency by reason of its resulting change in composition. In all the above the carrier is either wholly or partially separated from its original component substance by the pressure under the conditions involved When in addition to the above a comminuted absorptive body material such as chopped or ground fibers of wood, including cork, are used in the filler, the aforesaid change under pressure is still more marked, because the comminuted material, in the filler, as an article of manufacture, contains or has absorbed a modicum of water or of the colloidal compound, which (all as described at length in my application Serial No. 211,157 above) is pressed out or ejected when the laid filler'is compressed by the leveling pressure, and thereupon the then compressed body material at once, to the eX-' tent that it is released under the fillers spreading action in the shoe cavity, absorbs or takes into itself certain of the other constituents, if any, of the compound and of the sticky binder, or other form of binder as the case may be, thereby stiifening the laid filler layer and'giving permanency and firmness of position and of support to the filler layer and to the entire shoe bottom. Meanwhile the water or other compound or ingredient as it is being ejected acts as a lubricant to facilitate the movement of the filler material to the final position in the shoe bottom, and then the water evaporates, or if the filler material contains a compound which will unite'with it such as starch (or any other explained in my applications Serial Nos. 183,302 and 211,157) it unites to form paste, acting first as a slippery agent and then as a stiffener, by evaporation [or absorption. If oil or soluble oil is the compoundused, its action is the same when ejected in whole or in part and it is then absorbed, thereby giving increased stiffness, or enters further into the mixture as the case may be. In all these examples, the filler becomes more spreadable during the pressure, and then becomes less spreadable and stiffer subsequent thereto. The included water or other volatile, evaporable or absorbable compound is held inactive until the pressure or other means releases it. The filler material may be said to be composed of three parts, a body material and a binder which have a tendency to unit or an attracttion or affinity or intimacy, and means, such as the water, or a coating of dry starch enveloping the cork granules, or paste likewise, or other, constituting a barrier tending normally to restrain said union prior to use, but as soon as the filler in said condition and in the shoe bottom is subjected to pressure the barrier is thereby at once released. The barrier ingredient then acts flux for the filler material, rendering the latter temporarily more movable and more adherent. The ingredient which I have referred to as a barrier or dormant element encloses the cork or other body granules as a coating, like a skin, especially when gelatinous or as a thick paste, and inmy copending applications Serial No. 245,001 filed January 6, 1928, and Serial No.

245,002, filer. January 6, 1928, I have erplained further advantages and relations which not only may carry out the functions already described herein but greatlypromote lightnessof weight in the commercial procluct, cheapness of manufacture, keeping qualities (especially in the presence of damp ness), etc., and certain claims herein are 1ntended to be generic to the disclosures of all these applications, so far as this basic idea is present.

As shown-in Figs. 1 to 3 on a considerably enlarged scale, the filler piece, in the form of a large sheet at first before cutting into the sizes or pieces required for use, comprises preferably two covers or supporting layers 11 and 14 of paper or paper-like material or textile fabric 11 and 14 or any other suitable substance adapted to form' a protective skin, and an intermediate layer 15 of sticky plastic filler, so as to produce a resulting composite sheet of sufficient strength and coherence to be self-supporting, at least when cold, said supporting layers or covers 11, 1.4: being'preferably waterproof, at least on their inner surfaces next to the plastic layer 15. At least one of the outer layers is preferably of absorbent material. Preferably the fin ished sheets are coated or dusted on one or both sides with a substance adapted to deaden or dull any stickiness that may be present, intentionally or unintentionally, to prevent their sticking when piled for cutting and also if desired to make the surfaces of the final sheet actually slippery. Thus they may be dusted or coated with dry inert powder, for example a powdered mineral such as talc or soap stone which has an unctuous slippery feel or such mineral materials may be comv bined with organic substances, for example cork'dust or dry starch or the like may be used (which may become pasty'under the water treatment later). This is especially desirable if one of the webs, 14' or 14: for instance, omitted and replaced by such a layer T.

In preparing the individual filler pieces or leaves from the sheet as above described, I may proceed as indicated inFigs. 4 and 5 by providing regions of weakness in any manner, as by scoring the composite sheet on opposite sides, along lines 26 and 27, (Fi 4), to provide a series of superposed long and narrow panels 28, each flexibly united to adjacent panels by one of the outer skins and collec-. tively making a compact bundle. I now out through this bundle along transverse lines, which are preferably straight to minimize waste, dividing the bundle into blocks such as shown for example'in Fig. 5 where the block is of trapezoidal contour. This block now consists of a string of superposed sections 34:, 34-, etc., each of trapezoidalform, adjacent sections being flexibly united along their broader bases, as indicated at 35, and

along their narrow bases, as indicated at 36.

The individual sections 3-1- and 34 may beremoved from this seriesby cutting, tearing or otherwise, at the regions of weakness, previously mentioned, but I prefer to remove two such sections as a unit, as indicated in Fig. 8

where the sections 3 1 and 34 are shown as united along the line 35, thus forming the individual filler piece or leaf L. The above procedure just outlined is more full described in my copending application erial No. 192,076, filed May 17, 1927. As an alternative method of procedure in preparing the individual filler leaf, I may, as indicated in Fig. 6, cut through the thickness of a single sheet of the composite material, or through a series of piled up sheets, by means of a knife of zigzag form which forms a out such as in-- dicated at Z, Z in Fig. 6. By making a second out which is staggered with respect to the first cut I produce a string of fillervpieces or leaves L of the same form as the piece L shown in Fig. 8, but without, the transverse incision indicated at 35 in Fig. 8. These filler pieces L, of double trapezoidal form,

are weakly united at their small ends 36 (which may be made still more slender and therefore weak, if found desirable) and also, if desired, the strip or string of united filler pieces may be further weakened along the lines 36 by an incision, indentation, perforations, or otherwise to facilitate their subsequent ready separation.

Whether the materlal be prepared in accordance with the procedure of Figs. 4 and in preparation for subsequent use.

Having at hand the filler pieces as above explained, I am now ready for one of the most radically novel and important features of my present invention. It has heretofore been considered necessary to fasten the filler piece solidly in place in the shoe bottom cavity 25 by some means as, for instance, by a tack, which would occasionally work up through the inner sole in the subsequent wearing of the shoe. And even when, as sometimes, a piece of pasteboard or leatherboard has been used by the aid of a drop or dab of glue, it has always been stuck into the shoe-bottom cavity. The cavity has been the element to receive the piece, for the obvious reason that the piece heretofore used has had to be cut to fit the cavity, so that it was naturally then placed in said cavity. The operator would simply have made trouble for himself by attempting to put said shaped piece on the outer sole first. On the contrary, as a radical departure in nearly all respects, I provide first the filler in the form of a died-out piece as described, which is purposely not fitted or conformed tothe cavity which it finally occupies, but made of a shape quite different from the cavity'and preferably standard for all shapes of cavities and is purposely made smaller but expansible so as later to expand to fit the cavity. Also the filler piece is so shaped and constructed that it is entirely practicable to insert it into theshoe without extraneous or independent fastenin at the time of sole laying and prefdirect, simple and effective. To describe the method in detail I first immerse or thor oughly wet one of my filler pieces of any of the kinds noted, preferably dumping a quan tity of them into a water container.

hot Water, at the time of use, for the purpose of this process, even though they are Waterproof, at least next to the plastic inner layer (to prevent unoesired absorption of the layer 15 prematurely). The sole layer now takes a wetted piece quickly from the container or wetting basin or apparatus and simply lays it in proper position down on the'inner face of the outer sole 29. The outer surfaces 11 i and Li of the filler piece are capable of holding a water film on and in then external-sun faces With the result that when the filler piece is thus taken from the immersing basin and q ickly placed on the sole, this water film sticks the piece in place so to speak by rendcring the contacting surfaces temporarily friction-holding and also by the suction action due to the presence of the Water between the two perfectly flat, smooth surfaces. The water constitutes one form of temporary adhesive in this connection and for the purpose and environment of this process. The rest of the shoe (on its last as is customary) is now placed down in proper alignment on the sole and filler piece so that the shoe-bottom cavity receives or encloses properly the filler piece, as shown in bottom View in Fig.12, where the outer sole is omitted for clearness in showing the position just explained. This very readily donebecause the sole-laying operator simply exercises the same care that he has always had to exercise in placing the toe and side edges of the shoe with extreme care in accurate alignment-with the toe and as side edges of the sole (except that he has heretofore exercised this care in placing the sole on the cavity, instead of as now the cavity on the sole), and this results in automatic2. .y getting the filler piece Where it should be with relation to the cavity. In other words I simply provide a filler piece which can be placed readily and then I provide either in or on said filler piecejust enough friction surface or adhesive to prevent the cdgewise slipping or shifting of the piece The layer or layers 11, 14 of cover material are sufficiently responsive to Water, preferably during thefew moments until the shoe has been pressed down on the sole as stated. The sole layer then inverts the contacting shoe (With its last, etc.), sole-and filler piece, and holds it toa nailing machine which nails the sole at the toe, shank. and heel in usual manner, Whereuponthe'last is removed and the shoe goes to the sole stitcher. When stitched, as shown at 30, Fig. 14, it is ready for-the sole leveling operation, which is the finalimportant step of' my filling process. I have found thatiin practice this water film sufficient for'p'ractical purposes as merely a temporary adhesion is really all that. is needed at thispoint as permanent adhesion is secured by the squeezing out or spreading by the leveling pressureof'the intermediate plastic filler layer of the filler piece into the shoe cavity'beyond the boundary of the supporting layer orlayers of said piece, which effectually sticks or unites the entire filler layer permanently to the inner sole and the outer sole. Mainly I am describing my invention in co'nnectio'n'with McKay shoe manufacture, but this method of securingpermanent adhesion is 'of special value in filling welt shoes. But for still greater eiiiciency I prefer to provide the supporting'layer 'or layers themselves with an adhesive, preferably latent and brought into action by the immersion step. Also I preferably make the filler piece,ias"already explained, spreadable in wholeor in part with sticky material or at leastwith cavity occupying material so that when once leveled the filler piece is thereby rendered permanently unchangeable or unshiftable in positionx The immersion step of the process is preferably in hot water so as to condition the filler piece more rapidly as the laying ofthe filler piece occupies so much less time than the filling operation as heretofore practiced that it is advisable to have a large number of filling pieces being wetted. Nevertheless the filler piece itself is positioned really atnormal working temperature. In other words the hot water is not for melting the binder and does not in fact affect the binder, unless, for instance, paste-forming ingredients have been used in the filler piece. In the latter case the mar hesive. So also, although I have emphasized the fact thatthe hot water treatment is not for the purpose of conditioning the filler itself, it will be'understood'that a filler piece could be employed which would be conditioned by hot water treatment which in that case would be advantageous and within the purview and claims of this patent as to other steps and features. Such piece and its use would be in addition to certain other novel Such pre-treat-.

features of my invention. ment or conditioning and quickening per se is broadly claimed in my method application Serial No; 242,085 which is the generic method case as to employing quickening, and as to employing pressure, as to standard piece-application, asto employing latent adhesives (whether internal or external), as to employing a plastic piece,- with or without skin or cover support or supports, and as to anti-squeak applications and manipulation. Such piece and its use when not restricted to the other novel features of the present case is broadly contained and claimed in mycopending applications Serial No. 242,085 just mentioned, and Serial No. 228,588. The present application covers primarily a cold filler process and not primarily dependent on heat (excepting heat for quickening in connection with the cold process or with other steps of novelty of the process covered by the present application), whereas said application Serial No. 242,085 is the broad application covering generically the heat treatment process as such when applied to a piece and spreading the same. Said other last mentioned application covers broadly also any quickening process in connection with a filler piece as such, including the moisture quickening, hot or cold, of the piece as a piece of integral handleable layer for placing and spreading in a shoe-bottom. On the other hand, the use of hot water as above explained herein and so far as relates to the process of this application and the claims thereof is primarily simply for the wetting effect and the heat is simply to make it effective quicker by appreciably penetrating the paper or other cover more quickly than cold water would penetrate. The filler pieces are so constructed that they respond quicker to hot water than to cold water but it is simply the water or moisture that is relied upon and not the heat. The real laying of the filler is efiected by the leveling process which comes at a considerable period later when all the heat has long since left the positioned piece in the shoe-bottom cavity. My filler piece is constructed to spread at normal temperature, and this spreading does in fact take place at such subsequent period, viz. the time of leveling pressure, that even though the filler had originally become softened by the heat of the water immersion it would long since have become cold again and the actual spreading or shoe-bottom filling operation would be effect-ed cold or atnormal Working temperature. Reverting however to the contemplated more thorough conditioning of the filler material, as alluded to above, this is either by water or other means of rendering the surface of the filler piece active, or, the

filler material itself in the case of bulk filler,

or the surface and appreciablepenetration.

bring about such physical or chemical changes and conditions as the filler'composition provides for, and to render more flexible and pliable the skin or supporting layer, if any. For instance, numerous slipperyproducing compounds have been already set forth, and these can be rendered active or aided by the water treatment And instead of water, oil or emulsion producing solutions may be used. One important feature in this lineis in the case ofa filler piece without a protective skin and made non-sticky and dormant by any of the means mentioned as by a coating of talc or other dormant element, in which case the required conditioning may be by painting the surface with paraffin oil. The conditioning brings about, in any case, atemporary activity by rendering the tiller piece or material sticky, or slippery, pliable, more readily spreadable, and in general more responsive to the laying operation and the leveling, etc., and then the means employed therefor disappears largely or entirely, as by evaporation, absorption or conversion.

If the filler material be supplied to the shoe manufacturer in the form of string-like pieces of the kind shown in Fig. 7, or if it be cut into such pieces by the manufacturer, I find that one convenient method of procedure in applying these pieces to the shoe bottom consists in taking one of these strings of united filler pieces or leaves and throwing it over a convenient support, for example the shoulder of the operator,'thus leaving both of the operators hands free. The operator may now remove the endmost filler leaf or piece from the string by tearing, and attach it to the central part of the sole of the shoe with or, Without immersion treatment but preferably thoroughly wetted, as the latter is my preferred method or process as hereinafter claimed. The wetting step may be supplemented by using a portion or all of the sticky layer surface. While it is usually suflicient to remove a small part of the web and thus to expose only a relatively small spot of sticky material, I contemplate that the. web may be removed completely from one surface of the piece, if desired. Whether heres firmly and with sufficient tenacity so that there is no danger of displacement dur-' filler leaf to a hot plate or other surface for an instant just suificient to soften the sticky binder and thus free the skin or web so that it may be pulled off more readily. This application of heat is not intended to be sufiicient to soften the body of the plastic filler layer,but merely to soften the binder at the surface. While this softening of the binder just beneath the Web facilitates removal of the-web, it also makes the binder abnormally sticky so that it adheres to the shoe bottom very easily. 7

While I may remove a portion or all of the web, as' above described, after separation of the filler piece from the string orseries, I

find that it is very convenient to remove this.

section of the web concomitantly with the separation of the filler piece from the string.

This may be done, as indicated in Fig. 9, by

subjecting the endmost piece L to a slight twist as it is torn off from the next adjacent package, such action having a tendency to pull the uniting skin away from the plastic layer for a short distance, although I find that usually the web or paper will begin to tear, as indicated at C, Fig. 9, after a short portion has pulled off from the intermediate layer, thus exposing but a relatively small part 15 of the plastic filler material to form the attaching means.

In the McKay construction the plastic filler material is spread by the pressure over. the inner sole E and thence over the inner edges of the upper and fasteners F and the folds or plaits 26 upon the marginal portion of the inner sole. In a welt shoe this cavity is defined by the inseam and is usually deeper than that in a McKay shoe. Whether the filler leaf be applied to a McKayor a welt shoe, my process renders it unnecessary to make the same conform with any degree of exactitudeto the shape of the cavity. It will be understood that the usual shank piece or stiffener is applied and the heel seat completed in any usual manner and at the usual stage of operations. The outer sole 29 is secured to the shoe in any usual way, as by stitches indicated in Fig. 14, where a Mc- Kay shoe is illustrated. After the attachment of the outer sole, the shoe is subjected to the usual heavy pressure in a leveling machine, which completes the shoe-bottom ii ling operation asthe final step of my novel process. While undergoing this leveling pressure, the cold but plastic filler material 15 moves outwardly and then in whatever direction the cavity and circumstances make possible, exuding from between the webs 11 and 14 and filling the shoe-bottom cavityas well as all crevices and spaces between the folds of the edge portion of the upper. The exuded material 15 (Fig. 15) forms a smooth and level surface which engages the inner side of the inner sole as Well as of the outer sole and, as this exuded material is very sticky and adhesive it sticks also to the outer or marginal portions of the inner surface of the outer sole as well as to the edge'portions of the upper,

thus firmly uniting the outer sole to the up- I per and also to the inner sole so that the bottom of the shoe becomes practically a unit. With this construction it is possible to employ a thinner inner sole than is usual, since the inner sole is virtually plumped by the filler layer and is reinforced by the outer sole while the outer sole finds a uniform support over its entire area and is thus less subject to wear than when it is irregularly or inadequatedy supported, as heretofore. In filling a welt shoe it may be desirable to apply the spreading pressure before the outer sole is applied, as set forth in my application Serial No. 242,085 where various "features herein enumerated are still further explained largement or expansion in the shoe cavity irrespective of whether it is plastic or not. I have used the term spreadable filler piece or layer to define a plastic article which may be squashed or crushed and hence expanded in this way, i. e. by being moved one particle on another. A type of the eXpa-nsible filler piece which is not spreadable is described in the copending application Serial No. 212,747, filed August 13, 1927. A type of the expansible filler piece which is spreadable is described in my application Serial No. 133,506.

The adhesive binder is of a'waterproof nature as well as constituting an anti-squeak element and as it is forced outwardly into the crevices between the outer sole and the inturnd edge of the upper, itfornis a waterproof barrier which 'prevents-theentrance of water between the soles. As this'placing or positioning thereof is effected after the sole laying, it leaves the parts effectually waterpmofed or given an antHeak a an anti the convexity of the inner sole so that the space between thembecoznes very small and in many cases is negligible. Thus, after the completion of the leveling operation, these substantially contacting webs form a barrier which preventsany subsequent movement of theplastic filler material so that there is llttle possibility of bunching of the material durmg wear. Although the filler piece (of the preferred laminated type) is necessarily put in place before the leveling operation, the

'- coating.

sticky substance thereof is not interposed between the marginal portion of the inner surface of the outer sole and the adjacent shoe parts untilafter the outer sole is stitched'or otherwise fastened in place, whereupon said sticky substance is interposed as stated, thereby waterproofing said surfaces and especially the edges, crimped upper and irregularities bounding the cavity 25. Concomitantly with this spreading, the paper-like layers 11 and 14 are brought towards eachother in themiddle area into the space formerly occupied by the plastic filler which has just left or been pressed out. This constitutes a barrier, so positioned as to prevent any return movement of the extruded filler. In my application Serial No. 212,018, filed August 10, 1927, I have disclosed a method and article forfilling the shoe bottom by applying the filler piece marginally first and then pressing it or causing shifting inwardly toward the center instead of first applying the filler in the center and then shifting outward, and it will therefore be understood that, in its broader aspects, the present patent is generic to both methods.

Under some circumstances, to facilitate the lateral spreading or expansion of the filler piece, I may form a slit or slits 64 (as shown for example in the protector skin 24 in Fig. 10) in one or both of the skins 11 or 14, and when the slitted or incised piece is subjected to pressure, these slits widen and expose the plastic filler layer 15 which was previously held dormant or externally inactive but which noW readily exudes through these slits and adheres to contiguous parts of the shoe and also constitutes an anti-squeak sufficient filler material throughout the bottom and bring the parts into such mutually supporting and retaining relation as to make the shoe bottom anti-squeak (as duly claimed in my method case Serial No. 242,085, filed December 23, 1927). In the earlier part of this specification I have set forth a filler piece in which an element is held dormant chemically to be set free later for causing external adherence of the piece, and in Fig. 10 as just explained I accomplish said result mechanically by holding the internal layer, as for example the sticky layer 15 dormant by means of the outer skin or skins,

as 24 Fig. 10, until spread therefrom laterally and it may be therethrough, if slitted or fragile or permeable or otherwise removable as a dormant-maintaining means;

I have already at the beginning of this patent summarized certain leading features of novelty or steps and sequences of steps of my process, and I now enumerate these and others, but only in a general way, as I refer to the appended claims for a more complete enumeration and definition of my method and its detailed steps. My process is broadly In any event, my process forces.

squashable article (this feature, however, and

the next herein enumerated being new transferred to and claimed broadly in my appli-- tion Serial No. 242,085); and also preferably as a laminated piece; also'in bringing. into action in the shoebottom the stickiness of the filler layer by pressure as distinguished from heat; also in using a collodial element and changing the composition by heavy pressure; also in effectingthe spreading cold 7 or without heat treatment; also in effecting an increased inherent stifiening 'or resistance to subsequent shifting by applying heavy pressure to the filler layer; in accomplishing the last-enumerated step by the aid, in whole or in part, of included water; in providing absorbent and absorbed elements and manipulating them in the process; in providing abarrier to a binder element and removing it in the process; and in providing the automatic outlining of the ultimate filler layer, or, in other words, the automatic filling of the cavity, by the closing in approach of the inner sole and the outer sole towards each other; and, in making McKay shoes in beginning the filler laying on the outer sole; in doing this filling operation at the stage of the sole laying operation; in fastening the filler, as a piece, on the outer sole, preferably transiently; in completing the sole lay ing and sole fasteningwith the filling o eration not yet completed and soas to hole the filler piece fixed for subsequent expansion;- and finally in completing the filler laying operation or filler expansion step at the time of and by means of the sole leveling operation. 7 r i i While I have described a-certain order of steps as desirable in filling a shoe in accord{ ance with my present process, it will be understood that myinvention in many respec'tsis otherwise usable or adaptable. For example, in adapting my. process to the manufacture of welt shoes it is preferable to. fasten the. filler piece or pieces in the bottom cavity direct instead of on the outer sole. Hence, I

a quantity of plastic spreadable filler mate rial of different contour and smaller area than the cavity, and subjecting said filler material to a single stroke of pressure applied at the same time over the whole area'ofthe cavity and solely in a direction substantially vertical to the shoe bottom to spread the filler material to the confines of the cavity.

2. That process of filling shoes which comprises depositing in the bottom cavity of a shoe a quantity of plastic spreadable filler material suitable for filling the cavity but of smaller area and greater thickness than the cavity, then placing a pressing surface over the deposited filler and the cavity so as to enclose the cavity at andthroughout its peripheral upstanding rim, and applying pressure through said pressing surface in a substantially vertical direction to spread the filler to the confines of the closed cavity while said cavity is still closed against improper escape of the filler past said rim during the spreading of the filler.

3. That process of filling shoes, which comprises as steps providing an expansible filler piece, securing said piece in position on the inner face of the outer sole, assembling the rest of the shoe bottom and said outer sole and filler piece in proper relation for fastening the outer sole to the shoe-bottom, and then fastening said outer sole to the shoe-bottom with the filler piece against the cavity of the shoe-bottom, and spreading the filler piece by pressure.

4. That process of filling shoes, which comprises placing in a shoe-bottom cavity, a sheet-like piece of filler material having within it adhesive characteristics capable'of becoming effectively sticky with relation to adjacent shoe-cavity surfaces by pressure as distinguished from heat, and then applying to said piece pressure to stick the filler thereby in place.

5. That process of filling shoes, which comprises placing in a shoe-bottom cavity filler material containing a dormant, stifi'ening ingredient adapted to be rendered active by pressure, and then applying pressure to said filler material sufiicient to render said stiffening ingredient active in the filler material.

6. That process of filling shoes, which comprises placing in a shoe-bottom cavity spreadable shoe filler material which contains an admixture of free liquid, as distinguished from a solution of an ingredient of the filler material, adapted to be separated from the materials with which it is mixed by pressure, thereby to render the filler material stiffer and less liable to shift, and then applying pressure to said filler material sufiicient to separate said liquid and to effect said resistance to shifting tendency in the filler material.

7. That process of filling shoes, which comprises placing in the shoe bottom filler mateshoe-bottom, and then releasing said ingredi' ent by pressure and causing the same to act as a lubricant and facilitate the movement of said filler material to its said final position in the shoe-bottom. 1

10. That process of filling shoes, which comprises placing in the shoe bottom filler material containing an absorbent and an absorbed ingredient containing water, and separating the-same by pressure. V

11. That process of filling shoes, whic comprises placing in the shoe-bottom filler material which includes an absorbent containing an oily absorbed ingredient, and compressing the same sufliciently to release at least a part of the contained ingredient.

12. That process of filling shoes, which comprises placing in the shoe-bottom filler material containing an absorbent, an ab sorbed ingredient, and a compound cap able of unitingwith said absorbed ingredient when released, and thenreleasing said absorbed in gredient by pressure to unite with said compound.

13. That process of filling shoes which com prises placing in the shoe bottom filler material containing an absorbent, and absorbed ingredient, and a compound capable of unit ing with said absorbed ingredient when released to act as a lubricant and then as a stiffener, and then releasing said absorbedingredient by pressure tounite with said compound and effect said results.

14. That process of filling shoes, which comprises placing in the shoe-bottom filler material containing an absorbent, an absorbed ingredient, and a compound capable of uniting with said absorbed ingredient when released to act as a lubricant and then as a stiffener, and then releasing said absorbed ingredient by pressure to unite with said compound and effect said results, and thereafter permitting said released ingredient to produce further stiffness and compacting of the laid filler by subsequent absorption.

15. That process of filling shoes, which comprises providing as an article of manufacture a self-sustaining, shape-maintaining filler piece which is expansible, placing the same between the inner sole and outer sole in the shoe-bottom cavity, and then expandmg said piece within the confines of the cavity.

16. That process of filling shoes, which comprises providing filler material composed of at least three parts,-v iz. a body material and a binder, having atendency to unite, and means constituting a barrier tending normally to restrain said union prior to use,placing said filler material in the shoe bottom while in said condition, and then releasing said barrier by pressure and causing said union. 7 I 17. That process of filling shoes, which comprises providing filler material composed of at least three parts, viz. a body material and a binder, having a tendency to unite, and means constituting a barrier tending normally to restrain said union prior to use, placing said filler material in the shoe-bottom while in said condition, and then by pressure releasing said barrier and causing said union. 18. That process of filling shoes, which comprises providing filler material composed of at least three parts, namely, a body material and a binder, having a tendency to unite, and means constituting a barrier tending normally to restrain said union prior to use and capable on release of constituting a flux for the filler material, placing said filler mate rial in the shoe-bottom while in said condition, and then releasing sald barrler by pressure and causing said umon and using said barrier means to cause it to flux the filler and render it temporarily more movable.

19. That process of filling shoes, which comprises placing in the shoe abottom filler in the form of a sheet like piece containing an inactive element capable of becoming externally active and rendering the filler material adherent to the adjacent parts of the shoe bottom, and then rendering said inactive element active to cause said adherence. V g

20. That process of filling shoes, which comprises placing in the shoe a bottom filler material containing an inactive element re sponsive to pressureto be made active thereby so as to render the filler material adherent to the adjacent parts of the shoe bottom, and then applying pressure to render said inactive element active to cause said adherence.

21. That process of filling shoes, which comprises applying a plastic and spreadable but coherent and self-supporting filler leaf to a shoe-bottom, said piece having an area less than the area of the cavity and a thickness greater than the depth of the cavity, and subjecting said leaf at normal temperature to pressure suflicient to cause it to spread to the increased area and reduced thickness required to conform to the shape and dimenpiece having an area less than the area of the cavity and a thickness greater than the depth ofthe cavity, and spreading said layer to the increased area andv reduced thickness required to conform to the shape and dimensions of the cavity by the application of heavy pressure at normal temperature.

23.3That process of filling shoes, which comprises applying to the shoe bottom a filler leaf comprising a spreadable layer of sticky plastic filler and reinforcing means making said leaf normally coherent and shape retaining, and subjecting said leaf to pres sure While cold, thereby causing the plastic layer to spread relatively to its reinforcing means.

24. That process of filling shoes, which comprises applying to the bottomof a shoe a filler piece comprising a layer of sticky shoe filler'material having an outer skin on at least one side, securing the outersole to the shoe, and applying pressure to said piece through the outersole suflicient to cause said spiicky layer to spread beyond the edges of said s 1n.

25. That process of making shoes, which comprises as steps interposing a sticky substance between the central part of the outer sole and the inner sole of a shoe while ex inner sole and outer sole of the shoe a filler layer having a sticky moldable portion normally interposed between substantially non-' adhesive skins, and subjecting the shoe to leveling pressure whereby to cause the moldable filler to exude and form a'sticky edge around the skins.

27. That process of making shoes, which comprises as steps interposing a plastic substancebetween the inner sole and the central part of the outer sole of a shoe, and there after causing said plastic substance to flow outwardly toward the margin of the outer sole while concomitantly providing means tending to prevent subsequent movement of said plastic substance.

28. That process of making shoes, which comprises as steps interposing aplastic substance between the inner sole and the central. part of the outer sole of a shoe, and thereafter causing said plastic substance to spread outwardly toward the margin of the outer sole while concomitantly positioning a barrier to prevent its return. V

29. That process of making shoes, which comprises as steps interposing a plastic sub stance between the inner sole and the central part of the outer sole of a shoe, and thereafter causing said plastic substance to move outwardly toward the margin of the outer lit sole while concomitantly moving a non-plastic element into the space at the central part of the shoe formerly occupied by the outwardly moved plastic substance.

30. That process of making shoes, which comprises as steps interposing a plastic substance between the inner sole and the central part of the outer sole of a shoe, and thereafter causing said plastic substance to spread outwardly toward the margin of the outer sole while concomitantly moving a paper-like material into the space at the central part of the shoe formerly occupied by the outwardly spread plastic substance.

31. That process of making shoes, which comprises as steps providing a series of unite-d sheet-like pieces each comprising a layer of sticky filler material and a protective skin, tearing off a piece from the end of the series in such manner as at least partially to remove the skin from the separated piece, thereby exposing the sticky filler, and attaching the piece to the inner sole by means of the sticky filler so exposed.

32. That process of filling shoes, which comprises providing a shoe filler piece having a plastic sticky layer and a protective skin which is relatively non-adhesive, touching said piece to a hot surface to facilitate re moval of a portion at least of said skin, removing at least a portion of the skin, and applying the exposed sticky layer to a shoe bot tom.

33. That process of filling shoes, which comprises as steps providing a self-supporting filler piece consisting of a layer of plastic filler material combined with a layer of supporting material, the latter being provided with regions of weakness at some stage of its manufacture or use to reduce its resistance to lateral spreading, applying said filler piece to a shoe bottom, and subjecting said piece to pressure to cause it to expand laterally.

34:. That process of filling shoes, which comprises as steps preparing a coherent sheetlike piece comprising a layer of plastic sticky filler interposed between paper-like skins, slitting one of said skins to weaken it, plac ing the piece in the cavity of a shoe bottom, and subjecting said piece to pressure such as to spread it laterally and cause the slits to widen and expose the filler layer.

35. That process of making shoes, which comprises as steps providing a filler piece having a layer of plastic sticky material interposed between relatively non-sticky outer skins, providing a sticky spot on one side of said piece, applying said sticky spot to an element of a shoe-bottom to attach the filler piece thereto, placing the outer sole and rest of the shoe-bottom together, and leveling the shoe-bottom.

86. That process of filling shoes, which comprises as steps stripping off a portion at least of the protective skin from a filler piece comprising a layer of plastic sticky filler material and a protective skin, thereby exposing the sticky filler, attaching said piece to the bottom of a shoe by applying the exposed surface of the filler to one of the soles, and subjecting the filler piece to pressure toconform it to adjacent shoe parts.

37. That process of filling shoes, which includes as steps, providing filler material which comprises comminuted absorbent body material whose particles are enclosed with a removable barrier normally protecting said absorbent particles, and then removing said barrier from said previous protecting relation by pressure applied to the laid filler.

38. That process of filling shoes, which includes as steps, providing comminuted filler material whose particles are enclosed and protected by an external coating which is substantially permanent for purposes of handling and transportation and which then maintains the interior of said particles inaccessible to external influence, and then removing said coating as a protector by pressure in connection with the bottom filling operation.

39. That process of filling shoes, which comprises providing a self-sustaining, shapemaintaining filler piece which is expansible and is different in shape and smaller in area than the shoe-bottom cavity, placing the same 7 between the inner sole and the outer sole in the shoe-bottom cavity, and then expanding said piece to the confines of the cavity.

40. That process of filling shoes, which comprises applying to the shoe bottom a filler leaf comprising a layer of sticky plastic filler and reinforcing means making the leaf normally self-sustaining and shape maintaining, and subjecting said leaf to pressure while cold to spread the plastic layer to the shape of the contiguous surfaces of the shoe bottom.

41. That process of making shoes, which comprises as steps providing a series of united sheet-like pieces each comprising a layer of sticky filler material and a protective skin, tearing off a piece from the end of the series in such manner as at least partially to remove the skin from the separated piece, there- 7 by exposing the sticky filler, and attaching the piece to one of the surfaces forming the shoe-bottom cavity by means of the sticky filler so exposed.

Signed by me at Boston, Massachusetts this 2nd day of August, 1927.

ANDREW THOMA., 

